How to Cut T-slot?

How to Cut T-slot?

When cutting a T-slot, using the correct tools and techniques is crucial to achieve accuracy and safety. According to a featured snippet from Google, "Use a dedicated T-slot cutter or an end mill to achieve a precise cut, while ensuring the material is adequately clamped to avoid any movement during the process."

Essential Tools and Safety Measures

It's best to have a sacrificial fence behind the beam, even if it's just hardboard. This aids in preventing short cutoffs from being tossed by the blade. Using blue painter's tape to hold short cutoffs can also be beneficial. Simply run the tape from the workpiece, across the cut line and cutoff, and down to the table. If the cutoff is long enough, you can clamp it and skip the tape.

Using a Bandsaw

Go slow and let the blade do the work. While a bi-metal blade bandsaw can be noisier, it's highly effective. Using a 90/10 water/dish soap mix to lube the blade can help, although it can be messy. Smaller chips are an added benefit. For additional support, clamp the workpiece in a sliding table.

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Employing a Mitre Saw

The mitre saw works well if using a carbide blade. Ensure your saw has a blade with 60/80/120 teeth. My 12" saw with an 80-tooth carbide blade cuts beam efficiently. Since it generates a lot of noise and chips, using it outside is advisable. Safety gear, including hearing protection, long sleeves, and a face shield, is recommended unless you want to gamble with bodily harm.

Cutting 80/20 Aluminum T-Slot Extrusions

Sometimes, you might need to cut aluminum bars yourself, whether to save money or determine the exact length during the build. Aluminum’s weight-to-strength ratio and ease of cutting with a standard saw make it a practical choice.

Common Questions and Answers

Question 1: Can I use my circular or table saw?

Answer: Yes, but using the right blade and ensuring the squareness of the cut is important. Factory-cut aluminum t-slot bars use precise, calibrated saws for exact squareness. For a table saw, make sure the blade angle is 90 degrees and the bar is secured firmly before cutting.

Detailed Cutting Instructions for Circular Saws

If you're using a circular saw, ensure the base plate is parallel to the blade. Set the angle to 90 degrees and create a jig to stabilize the saw for a square cut.

Best Blade for Cutting Aluminum Extrusions

The recommended blade is a high-speed .375" steel blade with 60-72 teeth and carbide tips. Look for a double or triple chip blade with a flat “rager” tooth and a higher “trapeze” tooth for cutting harder materials like aluminum.

Lubricating the Blade

Lubricating the blade with vegetable oil or commercial lubricants like WD-40 or Trim Sol is essential. It helps prevent the blade from heating up and the chips from re-welding themselves to the blade teeth.

Adjusting RPM for Optimal Cutting

If your saw allows RPM adjustment, use a slower speed. The RPM needs to match the cutting speed and material thickness. Generally, aluminum requires a slower speed than wood to avoid heating the blade and lowering cut quality.

Safety Precautions

5 Safety Tips:

1. Always wear eye protection to guard against hot flying metal chips. A face shield is preferable.
2. Use hearing protection since cutting aluminum can be loud.
3. Consider respiratory protection due to the toxic dust from aluminum cutting.
4. Secure the bar firmly, preferably by clamping, to prevent it from moving during the cut.
5. Deburr the bar end using a polishing wheel, metal file, or sandpaper to avoid sharp edges.

Summary

Cutting 80/20 aluminum t-slot extrusions with common saws is easy if you follow these recommendations. Although cutting extrusions yourself can save money, having them cut by professionals ensures safety and precision.

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